Southwestern Industries ProtoTRAK Plus Service manual

ProtoTRAK®Plus
Programming, Operating & Service Manual
Southwestern Industries, Inc.
2615 Homestead Place
Rancho Dominguez, CA 90220 USA
T | 310.608.4422 |F | 310. 764.2668
Service Department: 800.367.3165
e-mail: [e-mail] | [e-mail] | web: southwesternindustries.com
Document: P/N 15692
Version: 070390

Copyright © 2008, Southwestern Industries, Inc. All rights are reserved. No part of this
publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by
any means, mechanical, photocopying, recording or otherwise, without the prior written
permission of Southwestern Industries, Inc.
While every effort has been made to include all the information required for the purposes of this
guide, Southwestern Industries, Inc. assumes no responsibility for inaccuracies or omission and
accepts no liability for damages resulting from the use of the information contained in this guide.
All brand names and products are trademarks or registered trademarks of their respective
holders.
Southwestern Industries, Inc.
2615 Homestead Place
Rancho Dominguez, CA 90220-5610
Phn 310/608-4422 Fax [phone]
Service Department
Phn 800/367-3165 Fax [phone]

ProtoTRAK Pl1r.s Progrnmming. Operaring & Cure Manual
Table of Contents
1 -0 Introduction ............................................. 1
2.0 Description .............................................. 2
Keyboard ............................................................ -2
..............................................................
Displays 3
Pendant Back Panel ................................................ -3
Power Control Cabinet ............................................. -3
.............................................................
2.5 Encoders -3
........................................................
2.6 ServoMotors -4
...............................................
2.7 Ball Screw Assembly -4
................................................
2.8 Tape Cassette Deck -4
3.0
Definitions. Terms. and Concepts .................... 5
.....................................
3.1 ProtoTRAK Axis Conventions 5
...............................
3.2 Absolute & Incremental Reference -5
...........................
3.3 Referenced and Non-Referenced Data -6
.....................................
3.4 Tool Diameter Compensation -6
..................................................
3.5 Connective Events 10
..............................
...................
3.6 CONRAD .... -10
4.0
DRO. JOG. POWER FEED Operation .............. 12
..........................................................
4.1 Clear Entry 12
4.2 IN to MM or MM to IN ............................................ 12
.....................................................
4.3 Reset One Axis 12
................................................................
4.4 Preset 12
4.5 Reset Absolute Reference ......................................... 12
.........................................
4.6 Preset Absolute Reference 12
............................
4.7 Recall Absolute Position of All Axes 12
4.8 Recall Absolute Position on One Axis ........................... 13
..................................................
4.9 Feedrate Ovemde 13
4-10 JOG .................................................................. 13
.........................................................
4.1 1 Power Feed 14
5.0
Programming & Program Run ........................ 15
. .
...................................
. 5 ! Incremental Reference 120sltion 15
...........................................................
5.2 CONRAD 15
.................. 5.3 POSITION or DR[L,I.. (POSN/DRII, L) Events 16
...............................................
5.4 BOLT HOLE Events 17
........................................................
5.5 MILI, Events 18
........................................................
5.6 ARC Events -20
.....................................................
5.7 CIRCLE Events 22

ProloTR,.lK Pll~s Progratnrning. Oporurit1y & Care Mnnuul
...................................................
5.8 POCKET Events -24
....................................................
5.9 REPEAT Events 26
...........................
5.10 Start, Stop and Running Several Parts 28
5.11 Editing
.............................................................. 29
..........................................
5.12 Tape CassetteOperation 34
...........................................
5.13 RS232 Communications 37
..................................................
5.14 Program Sample -39
6.0
DO ONE Operation . Program & Run .............. 42
...................................
6.1 Incremental Reference Position 42
........................................
6.2 DO ONE Program & Run
-42
.....................................................
6.3 Cutting Comers 43
6.4 DO ONE Editing .................................................. -44
7.0 Math Help ............................................... 45
...........................................................
7.1 Procedure -45
..................................................
7.2 Math Help Types -46
8.0 Care & Service ......................................... 54
..............................................
8.1 General System Care -54
...............................................
8.2 Data Error Messages 54
....................................................
8.3 Fault Messages -56
....................................
8.4 ProtoTRAK Limited Warranty 57

Section 1 Introduction 1 I
1.0 Introduction
Congratulations! Your ProtoTRAK is a unique, one-of-a-kind, control system which
combines the simplicity of manual machining with the contouring capability of CNC
controls.
The ProtoTRAK has been designed to maximize the interplay between manual and
automatic machining.
o
It acts like an advanced digital readout in manual machine
operation.
o It acts like
a CNC when programmed to do complex contouring
jobs.
o And it acts with the best qualities of each when your job is best
done
by transitioning back and forth between manual and contouring CNC
operations with the powerful DO ONE routines.
Section
2 provides a brief description of the ProtoTRAK.
Section
3 defines some terms and concepts useful in learning to program and operate
the ProtoTRAK.
Section
4 describes the digital readout (DRO), jog, and power feed operation of the
ProtoTRAK.
Section
5 describes general programming and program run.
Section
6 describes programming and running DO ONE routines.
Section
7 describes the Math Help features built into the ProtoTRAK.
Section 8 provides some suggestions for the proper care and maintenance as well as
error messages.

Secrion 2 Descriprio~r 1 2
2 -0 Description
2.1 Keyboard (Figure 1)
All of the data required to properly program and operate the ProtoTRAK is input
through
the keyboard. This sealed polycarbonate front panellkeyboard will beep when
proper contact has been made with
each key.
X, Y, Z: selects axis for subsequent commands.
DO ONE: calls up single cycle routines.
POSN DRILL: callsup the positionldrill routine.
BOLT
HOLE: calls up bolt hole routine.
MILL: calls up the straight line mill routine.
ARC: calls up the arc mill routine.
CIRCLE: calls up circular pocket or frame routines.
REPEAT: calls up programming of subroutines.
POCKET: calls up rectangular pocket or frame routines.
START: initiates the start of a program or
DO ONE.
PWR FEED: activates power feed routines.
FEED?: feedrate override to increase feedrate.
FEED& : feedrate override to decrease feedrate.
INC SET: loads incremental dimensions and general data.
ABS
SET: loads absolute dimensions and general data.
INIMM: causes English to Metric or Metric to English conversion of displayed data.
TAPElRS232: calls up read or write cassette tape program storage and CAD/CAM
interface routines.
INCIABS: switches all or one axis from incremental readout to absolute or absolute to
incremental .
RESTORE: clears an entry, aborts a keying procedure, restores ;l failure or warning
indication, and aborts Math
Help.
STOP: halts motion during program or DO ONE run.
GO: continues rnotion after STOP, actuates jog routine.

MATH HELP: calls up Math Help routines.
EDIT: calls up recall, add event, delete event, and special mode routines.
RECALL DATA: cycles readout through programmed data.
* : not used.
0-9, +I-, . :
inputs numeric data with floating point format. Data
is automatically + unless +I- key is pressed. All input data
automatically rounded to the system's resolution.
2.2 Displays (Figure 1)
X, Y, Z: shows current position or data being entered during
program or
DO ONE input. Non-dimensional program or DO ONE
input will always be displayed in 2. A red dot above the +/-
display indicates absolute dimensions are being displayed.
EVENT: shows event number and type being programmed or run.
D indicates a position/drill event; B for Bolt Hole; M for Mill;
A for Arc; R for Repeat, C for Circle, and P for Pocket.
CONVERSATION: shows prompting messages for the operation during program and
Nn.
SERVOS ON: indicates that the DC servo motors and amplifiers are turned on.
IN POSITION: indicates that the tablelsaddle have stopped moving
and the ProtoTRAK awaits further input.
2.3 Pendant Back Panel (Figure 2)
See Figure 2 for a description of the fuses, switches, and
connectors
on the pendant back panel.
2.4 Power Control Cabinet (Figure 3)
The power control cabinet contains the unique SWI digital servo
amplifiers which drive the
DC servo motors. See Figure 3 for a description of the
connectors located on the side.
2.5 Encoders
The encoders used to provide dircct table and quill position
feedback to
the I'roto'I'RAK are sealed against typical shop environ-
men ts and utilize the time proven gage-wheel principal. Model
M250C is used all axes.

Section 2 Description 1 4
2.6 Servo Motors
The servo motors are rated 280 in-oz maximum continuous torque which are sufficient
for the heaviest cuts.
2.7 Ball Screw Assembly
The normal acme leadscrews are replaced with zero backlash ball bearing leadscrews to
provide accurate positioning and precise contouring.
2.8 Tape Cassette Deck (optional)
The cassette deck allows all programs to be saved on tape for future run. The deck is
held in a separateenclosure which
can be easily moved from one ProtoTRAK to another
or used with a TRAK CNC or TRAK CNC 2.
Additional tapes may be obtained by contacting:
SouthwesternIndustries,
Inc.
2605 Homestead Place
Rancho Dominguez,
CA 90220
2131608-4422
FAX [phone]

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POWER CONTROL CABINET
(Side View)
X Motor
Connector
.(im). d Pendant
Logic
Connector
I Switch
FIGURE 3 1

Section 3 Deiinjtions, Terms. and Concepts 1 5
3.0 Definitions, Terms, and Concepts
3.1 ProtaTRAK Axis Conventions
X Axis - Positive X axis motion is defined as the table moving to the left
when facing the mill. Consequently, measurement to the right is positive
on the workpiece.
Y Axis - Positive Y axis motion is dehed as the table moving toward the
operator. Measurement toward
the machine (away from operator) is
positive on the workpiece.
Z Axis - Positive Z axis motion is defined as moving the quill up.
Measurement up is also positive on the workpiece.
3.2 Absolute & Incremental Reference
The ProtoTRAK may be programmed and operated in either (or in a
combination) of absolute or incremental dimensions. An absolute reference
from which all absolute dimensions are measured (in DRO, DO ONE and
program operation) can be set
at any point on or even off the workpiece.
To help understand the difference
between absolute and incremental
position consider the example below:
1 Absol ute Dimensions
A.bsolute
Reference
Iricremental Diinension5

3.3 Referenced arid Non-Referenced Data
Data is always loaded into the ProtoTR4.K by using the INC SET or
US SET key. In entering any X, Y, or Z position data the operator
must note whether it is an incremental or absolute dimension and
enter it accordingly.
All other information, such as tool diameter,
feedrate, etc. is not
a position and may, therefore, be loaded with
either the INC SET or ABS SET key.
3.4 Tool Diameter Compensation
Tool diameter compensation allows the machined edges shown direct-
ly on
the print to be programmed instead of the center of the tool.
The ProtoTRA.K then automatically compensates for the programmed
geometry so that the desired results are obtained.
If the cutter in the sketch above is moving from left to right from
point XI, Y1 to X2, Y2 and on to X3, Y3 then these actual points can
be programmed instead of the center of the cutter.

Section 3 Definibbns, Terms, and Concepts 1 7
Or for the sketch above the actual desired circle with radius R can be
programmed instead of the radius of the center at the cutter Rc.
Tool
cutter compensation is always specsed as the tool either right or left
of the workpiece while looking in the direction of the tool motion.
Below are examples of tool right:
Examples of tool left are:
Tool center means no compensation either right or left. That is, the
centerline of the tool will be moved to the programmed points.

3.4.1
Special Small Step Milling Situation
Ln cases where tool diameter compensation is to be used to mill
a connective step whose length is less than the tool radius, an
offset distance must be calculated and used to adjust the
beginning or ending point (depending on the direction of
the
milling cut) of the event.
- 7 '3
X4, Y4
XI, Y1
In the figure above, to mill from XI, Y1 to X2, Y2 to X3, Y3 to
X4, Y4 when the length of the step from X2, Y2 to X3, Y3 is
less than
the radius (R) of the tool, point X2, Y2 would have to
be offket toward point
XI, Y1 by a distance equal to d. d can
be calculated using the following formula:
where
R = tool radius
L = length of step from X2, Y2 to X3, Y3
(2) For rough machining d may be estimated quickly by
multiplying the tool diameter by 0.15.
CAUTION: Using this method may result in larger than necessary
offsets
when the step is very small and the tool
diameter
is very large.
The following examples show how d map be calculated and
estimated. Example
2 iilustrates how a larger than necessary
offset results when a large tool is used and d is estimated.

Section 3 Definirions Terms,. and Concepts 1 ,9
EXAMPLE 1
Let XI = 0" ABS Using Formula 1 to calculate d:
Y1 = 0" AB *
= 1,~ d ABS !.r,ri!z
d = (.125-.050) (4~)
Y2 = 0" ABS
2(.125)-.050
X3 = 1.500" ABS d = (.075)
Y3 = 0.050" ABS (m)
X4 = 3.000" ABS
d = (-075) (G)
Y4 = 0.050" ABS
Tool Diameter = .250" d = (.075)(.5)
Using (2) to estimate d:
By using d calculated X2 would d = (.25)(.15)
be adjusted to 1.462" ABS for d = .038
programming
EXAMPLE 2
Let X1 = 0" ABS Using Formula 1 to calculate d:
-
Y1 = 0" ms
X2 = 1.500" ABS
d = (-375-.010) (-)
Y2 = 0" ABS
X3 = 1.500" ABS
d = (.365) (m)
Y3
= 0.010" ABS
X4 = 3.000" ABS
d = (.365) (F)
Y4 = 0.010" ABS
\ /
Tool Diameter = ,750" d = (.365)(.116)
Using (2) to estimate d:

3.5 Connective Events
Connective events occur between two milling events (either MILL or
ARC, but not CIRCLE) when the X, Y, and Z ending points of the first
event are in the same location as the X, Y, and Z starting points of
the next event. In addition, the tool ofFset-s and tool number of both
events must be the same.
3.6 CONRAD
CONRAD is a unique feature of the ProtoTRAK in that it allows the
operator to program a tangentially co~ectingradius between connec-
tive events
or tangentially connecting radii for the corners of
pockets
and kames without the necessity of complex calculations.
A few typical examples of CONRAD applications are described below.
For
the figure below, the operator simply programs a MILL event from
XI, Y1 to ,W, Y2 with tool right offset and another MILL event from
X2, Y2 to X3, Y3 also with tool right offset. During the programming
of the first MILL event the system will prompt for CONRAD at which time
the operator inputs the numerical value of the tangentially connecting
radius (r=k). The system will calculate the tangent points TI and TZ
and direct the tool cutter to move continuously from XI, Y1 through TI,
r=k, T2 to X3, Y3.

kction 3 Def?njh'ons Terms, and Concepts I 11
For the figure below, the operator simply programs an ARC MILL event
from
XI, Y1 to X2, Y2 with tool offset left and another ARC MILL event
from
X2, Y2 to X3, Y3 also with tool ofFset left. During the
programming of the first ARC MILL event the system will prompt for
CONRAD at which time the operator inputs the numerical value of the
tangentially co~ectingradius r=K3.
The system will calculate the tangent
points
TI and T2 and direct the tool cutter to move continuously from
XI, Y1 through TI, r==, T2 to X3, Y3.
NOTE: CONRAD must always be the same or larger than the tool radius
for inside corners.
Lf CONRAD is less than the tool radius and
an inside corner is machined, the ProtoTRAK will ignore the
CONRAD.

Secrion 4 DRO, JOG, POWER FEED Operation 1 12
4.0 DRO, JOG, POWER FEED Operation
The ProtoTRAK operates in manual operation as a sophisticatedthree-axis
digital readout
(DRO) with jog and power feed capability.
4.1 Clear Entry
Press RESTORE, then re-enter all keys.
Press
WIMM and observe position of decimal point to determine
measurement mode.
4.3 Reset One Axis
Press X or Y or 2, INC SET. This zeros the incrementalposition in the
selected axis.
4.4 Preset
Press X or Y or 2, numeric data, INC SET to preset selected axis.
4.5 Reset Absolute Reference
Press X or Y or 2, ABS SET to set selected axis absolute to zero at the
current position. See
4.7 and 4.8 to display this data.
NOTE: This will also reset the incremental dimension if the absolute
position is being displayed when it is reset.
4.6 Preset Absolute Reference
Press X or Y or 2, numeric data, ABS SET to set the selected axis
absolute to
a preset location for the current machine position.
See 4.7
and 4.8 to display this data.
NOTE: This will also reset the incremental dimension if the absolute
position
is being displayed when it is preset.
4.7 Recall Absolute Position of All Axes
Press TWC/ABS. Note presence of red dot above each +I- to determine if
the axis is reading incremental (no red dot) or absolute data (red dot).
Press
INC/ABS again to revert to the original reading.

4.8 Recall Absolute Position on One Axis
Press X or Y or Z, INCJABS. Note presence of red dot above selected
axis
+I- to determine if the axis is reading incremental data (no red dot)
or absolute data (red dot). Repeat to get selected axis back to original
reading.
4.9 Feedrate Override
The feedrate may be modified during any program run (including while the
table
is moving), during Jog operation, and during Power Feed operation
(see 4.10 and 4-11below).
Pressing and holding the
FEED& key will slow the feed down. The FEED
key increases the feed in the same way. The limits are 10percent to
150 percent of the programmed rate, but not faster than the 100 inches
per minute rapid speed. The feedrate change will always stop as it passes
100%. Release the key and press again to continue the change.
While the
Feed?, or Feed\Lkey is pressed, and for one second following
release, thepercent feedrate (or actual feedrate for power feed) will be
shown in the conversation display.
4.10 JOG
The servo motors can be used to jog the table. To jog at rapid (100
ipm):
a) Press and hold for
3 seconds the GO key.
b) The conversation display will flash "JOG+"or "JOG-" and the Servo On
display will be lit.
c)
Press the X key to move at rapid speed in the X direction shown.
d)
Press the Y key to move at rapid speed in the Y direction shown.
e) Press
+/- key to switch between " +" and "-" jog direction.
f) Press
FEED?, or FEEDbkey to change feedrate. The conversation
display will show the percentage feedrate override.
g) Press
RESTORE to cancel jog operation.
For slower jog speeds:
Use the same procedure as above except press a two-digit feedrate (2 7
means to feed at 27 ipm) prior to pressing X or Y.
The new feedrate
(27 in the above example) can now be modified by the feedrate override.
The feedrate can be changed at any time by releasing X or Y, inputting a
new two-digit rate, and re-pressing X or Y.